© The Energy and Resources Institute 2019

T E R I. 2019

Increasing Rail Share in Freight Transport in India : Working Paper – Fly Ash

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Figure 1: Process showing Handling and Storage of Fly Ash 11

Figure 2: Photograph showing Fly Ash Loading Silos and Road Bulkers 12

Figure 3: Scenario of Fly Ash Generation in India 13

Figure 4: Scenario of Fly Ash Utilization in India 13

Figure 5: An Overall Scenario of Fly Ash Production in India 13

Figure 12: Major Origin and Destination Nodes for Transporting Fly Ash through Railways 23

Figure 13: Various type of Wagons used in transporting fly ash via Rail 24

Figure 14: Covered Car “BCCW’’ wagon for bulk transport of Cement/Fly Ash 24

Figure 15: BCCW wagons for bulk transport of Cement/Fly Ash 24

Figure 16: BTAP Wagon 24

Figure17: ShareofPPCcementandOPCcementintotalcementproduction 25

Figure18: SpatialdistributionofCementplantsinIndiaalongwiththeThermalPowerPlants(BufferRange–100km) 26

Figure19: SpatialdistributionofCementplantsinIndiaalongwiththeThermalPowerPlants(BufferRange–300km) 27

Figure 20: Pneumatic Unloading Facility for Bulker Trucks at Prism Cement, Satna 29

Figure 21: Mechanized fly ash unloading through Truck Tippler at Prism Cement, Satna 29

Figure27: MapshowinglocationofSingrauliRegion 35

Figure 28: Map showing location of Thermal Power Stations in Singrauli Region and Cement Plants in Rewa-Satna Region 36

Figure 29: Annual Rail and Road Cost Comparisons for Cement Plants 38

Figure 30: Comparison of Annual

Table 1: Annual Backlog of Fly Ash along with Percent of Utilization 14

Table 2: State wise scenario of fly ash production in India 15

Table3: ListofTop20ThermalPowerStations(TPS)inIndiaintermsofGenerationofFlyAsh 17

Table 4: Mode of Fly ash Utilization 19

Table 5: Scenario of Fly Ash Transport by Indian Railways 21

Table7: MajorOriginNodesintermsofFlyAshTransportthroughIndianRailways 22

Table 8: Major Destination Nodes in terms of Fly Ash Transport through Indian Railways 23

Table16: AnnualestimatedcostsfortransportingyashfromSingrauliregiontoCementPlantsbyRail 37

Table17: ComparisonofRoadandRailcostsaswellasrespectiveSavings 38

Table 18: Assumptions taken for calculating savings in

Table 19 : Savings in

TheEnergyandResourcesInstitute(TERI)wouldliketoexpressdeepgratitudetotheMemberTrafcandRailway

We also extend sincere gratitude to Shakti Sustainable Energy Foundation in supporting TERI to undertake this study.

The project team also acknowledges the contribution of Mr Shri Prakash, Distinguished Fellow, TERI, and Mr Deepak

Nath, Independent Consultant and Ex-Railway Personnel towards reviewing and enriching the study with their

valuable suggestions and experience of the railways sector. We take this opportunity to thank the editorial and design

team at TERI for their contribution.

Table 1 represents the details of fly-ash backlog along

with the utilization percentage. Lower utilization of

fly ash over the years has led to the piling up of huge

stocks of fly ash. The table makes it evident that a total

of 1,332 million tonnes of fly ash has been stocked on

groundasof2016–17,ofwhichonly107milliontonnes

of the total fly-ash generation in the country. Figure 6

shows the state-wise production of fly ash in the country.

It is evident from the map that Uttar Pradesh and

Chhattisgarh produce the maximum fly ash, whereas

Punjab, Haryana, Karnataka, and Telangana are the states

with least production.

resourceful commodity. The current major modes of fly-

ash utilization in the country as per the CEA are shown

in Table 4.

Table 4 shows that cement manufacturing has the

1.5 million tonnes in 2011–12 to 2.5 million tonnes in

2016–17.Althoughwhencomparedtothetotalyash

transported, the share of Indian Railways is substantially

fly-ash movement by rail.